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Harley Davidson 2009 Dyna Models. Service manual - page 25

A.4

DELPHI MAXI FUSE HOUSING

DELPHI MAIN FUSE HOUSING REPAIR

General

A Delphi Main fuse connector completes the circuit through
the main fuse.

Removing Main Fuse

See

Figure A-12

. Depress latches on main fuse cover (1)

and then slide cover off of connector (2).

Holding the connector (fuse holder), pull the main fuse out
of the connector.

Installing Main Fuse

Insert the blade terminals of the main fuse into the sockets
of the connector and press the main fuse into the con-
nector.

Slide the cover over the fuse until the cover clicks into
place.

NOTE

If removed from an OE attachment such as a grooved fuse
block cover, engage cover and slide into place.

Removing Socket Terminals

See

Figure A-13

. Gently pull socket housing to disengage

slots (1) on secondary lock (2) from tabs (3) on socket
housing. Free secondary lock from cables and set aside.

Take note of the opening on one side of the socket ter-
minal. Gently insert flat blade of pick (Snap-On TT600-5)
or small screwdriver into opening (4) until it stops. Pivot
the pick toward the terminal body and hold in position.

Tug on cable to pull socket from wire end of socket
housing. A firm tug is necessary to overcome the resist-
ance of the rubber seal.

Repeat to remove remaining socket terminal.

Installing Socket Terminals

See

Figure A-14

. Carefully bend tang outward away from

the terminal body.

Feed socket into wire end of socket housing until it clicks
in place. Verify that socket will not back out of chamber.
A slight tug on the cable will confirm that it is locked.

Push rubber seal into wire end of socket housing.

Repeat to install remaining socket terminal.

Install secondary lock onto cables and then push onto wire
end of socket housing until slots engage tabs on sides of
socket housing.

sm00032

Main fuse cover

Delphi main fuse housing

Figure A-12. Delphi Connector Housing: Main Fuse

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A-8 2009 Dyna Service: Appendix A Connector Repair

sm00033

Secondary lock slot

Secondary lock

Tab

Insert flat blade into opening

Figure A-13. Delphi Main Fuse Housing: Remove Socket

Terminals

sm00034

Figure A-14. Delphi Main Fuse Housing: Bend Tang

HOME

2009 Dyna Service: Appendix A Connector Repair A-9

A.5

DEUTSCH ELECTRICAL CONNECTORS

DEUTSCH CONNECTOR REPAIR

TOOL NAME

PART NUMBER

DEUTSCH CONNECTOR SERVICE
KIT

HD-41475

FLAT BLADE L-HOOK

HD-41475-100

General

Deutsch connectors are colored coded for location purposes.
Those connectors associated with left side accessories, such
as the front and rear left turn signals, are gray. All other con-
nectors, including those associated with right side accessories,
are black.

NOTE

A DEUTSCH CONNECTOR SERVICE KIT (Part No. HD-
41475) contains a selection of wire seals, internal seals, seal
plugs, secondary locking wedges, attachment clips and
socket/pin terminals. Also included is a compartmented storage
box, carrying case and a FLAT BLADE L-HOOK (Part No. HD-
41475-100) is used for the removal of all types of locking
wedges.

Separating Pin and Socket Housings

See

Figure A-15

. To separate the connector halves, depress

the external latch(es) (1) on the socket housing (2) while
rocking the pin (3) and socket housings.

NOTES

•

Generally, the socket housing is found on the accessory
side, while the pin housing is plumbed to the wiring har-
ness.

•

Two-, three-, four- and six-place Deutsch connectors have
one latch on the connector.

•

Eight- and twelve-place connectors have a latch on each
side. Simultaneously press both latches to separate the
connector.

Mating Pin and Socket Housings

Align the connectors to match the wire lead colors.

For One External Latch: Two-, three-, four- and six-
place Deutsch connectors have one external latch on
the socket half of the connector. To fit the halves of
the connector together, the latch on the socket side
must be aligned with the latch cover on the pin side.

For Two External Latches: (8-place and 12-place)
Align the tabs on the socket housing with the grooves
on the pin housing.

Insert socket housing into pin housing until it snaps or
clicks into place.

For Two External Latches: (8-place and 12-place) If
latches do not click (latch), press on one side of the con-
nector until that latch engages, then press on the opposite
side to engage the other latch.

If necessary, fit the attachment clip to the pin housing.

Place large end of slot on attachment clip over T-stud on
frame. Push assembly forward to engage small end of
slot.

sm00017

External latch

Socket housing

Pin housing

Figure A-15. Deutsch Connector

Removing Socket Terminals

See

Figure A-16

. Insert a small screwdriver between the

socket housing and locking wedge in-line with the groove
(in-line with the pin holes if the groove is absent). Turn the
screwdriver 90 degrees to pop the wedge up and remove
the secondary locking wedge.

See

Figure A-19

. Use a pick or small screwdriver to

depress terminal latches inside socket housing and back
out sockets through holes in rear wire seal.

NOTE

If wire leads require new terminals, see the instructions for
crimping terminals.

Installing Socket Terminals

Match wire lead color to connector cavity.

See

Figure A-18

. Fit rear wire seal (1) into back of socket

housing (2), if removed.

Grasp wire lead (3) approximately 1.0 in. (25.4 mm) behind
the socket terminal. Gently push socket through hole in
wire seal into its chambers until it "clicks" in place.

A tug on the wire will confirm that it is properly locked in
place.

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A-10 2009 Dyna Service: Appendix A Connector Repair

NOTE

Seal plugs (6) are installed through the wire seals of unused
chambers. If removed, seal plugs must be replaced to seal the
connector.

Install internal seal (4) on lip of socket housing, if removed.

Insert tapered end of secondary locking wedge (5) into
socket housing and press down until it snaps in place. The
wedge fits into the center groove within the socket housing
and holds the terminal latches tightly closed.

NOTES

•

See

Figure A-17

. While rectangular wedges do not require

a special orientation, the conical secondary locking wedge
of the 3-place connector must be installed with the arrow
(1) pointing toward the external latch.

•

If the secondary locking wedge does not slide into the
installed position easily, verify that all terminals are fully
installed in the socket housing. The lock indicates when
terminals are not properly installed by not entering its fully
installed position.

sm00009

Figure A-16. Deutsch Connector: Remove Secondary

Locking Wedge

sm00018

Arrow on socket locking wedge

Arrow on pin locking wedge

Figure A-17. Deutsch Connector: 3-Place Locking Wedges

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2009 Dyna Service: Appendix A Connector Repair A-11

DEUTSCH

sm00010

Wire seal

Socket housing

Wire lead

Internal seal

Secondary locking wedge

Seal plug

Figure A-18. Deutsch Connector: 2, 3, 4 and 12-Place

Socket Housings

Removing Pin Terminals

Use the hooked end of a stiff piece of mechanics wire, a
needle nose pliers or the FLAT BLADE L-HOOK (Part
No. HD-41475-100) to remove the secondary locking
wedge.

Gently depress terminal latches inside pin housing and
back out pins through holes in wire seal.

NOTES

•

If wire leads require new terminals, see the instructions
for crimping terminals.

•

If it should become necessary to replace a pin or socket
housing, please note that the 8-place and 12-place gray
and black connectors are not interchangeable. Since loc-

ation of the alignment tabs differ between the black and
gray connectors, plugs or receptacles must be replaced
by those of the same color.

•

When replacing both socket and pin housings, then the
black may be substituted for the gray, and vice versa. The
socket and pin housings of all other connectors are inter-
changeable, that is, the black may be mated with the gray,
since the alignment tabs are absent and the orientation
of the external latch is the same.

sm00019

Figure A-19. Deutsch Connector: Depress Terminal Latch

and Back Out Pin

Installing Pin Terminals

See

Figure A-20

. Fit wire seal (1) into back of pin housing

(2).

Grasp wire lead approximately 1.0 in. (25.4 mm) behind
the pin terminal (3). Gently push pin through holes in wire
seal into its respective numbered chamber until it "clicks"
in place.

NOTE

A tug on the wire lead will confirm that a pin is locked in place.

Insert tapered end of secondary locking wedge (4) into
pin housing and press down until it snaps in place.

NOTES

•

The wedge fits in the center groove of the pin housing and
holds the terminal latches tightly closed.

•

See

Figure A-17

. While rectangular wedges do not require

a special orientation, the conical secondary locking wedge
of the 3-place connector must be installed with the arrow
(2) pointing toward the external latch.

•

If the secondary locking wedge does not slide into the
installed position easily, verify that all terminals are fully
installed in the pin housing. The lock indicates when ter-
minals are not properly installed by not entering its fully
installed position.

HOME

A-12 2009 Dyna Service: Appendix A Connector Repair

DEUTSCH

sm00020

Wire seal

Pin housing

Pin terminal

Locking wedge

Figure A-20. Deutsch Connector: 2, 3, 4 and 12-Place Pin

Housings

Crimping Terminals

Identify which of the types of Deutsch terminals are used with
the connector and follow the corresponding crimping instruc-
tions. Refer to

Table A-2

Table A-2. Deutsch Connector: Terminal Crimping Instructions

CRIMPING INSTRUCTIONS

TYPE

A.6 DEUTSCH STANDARD TERMINAL REPAIR

Standard (with crimp tails)

A.7 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR

Mini Terminal (solid barrel)

A.8 DEUTSCH MINI TERMINAL REPAIR

Mini Terminal (with crimp tails)

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2009 Dyna Service: Appendix A Connector Repair A-13

A.6

DEUTSCH STANDARD TERMINAL REPAIR

DEUTSCH STANDARD TERMINAL CRIMPS

TOOL NAME

PART NUMBER

DEUTSCH TERMINAL CRIMP TOOL

HD-39965-A

Preparing Wire Leads for Crimping

Use a shop gauge to determine gauge of wire lead.

Strip lead removing 5/32 in. (4.0 mm) of insulation.

Crimping Terminal to Lead

See

Figure A-21

. Squeeze the handles of the DEUTSCH

TERMINAL CRIMP TOOL (Part No. HD-39965-A) to open
the jaws. Push the locking bar (1) up.

Insert (2) terminal (socket/pin) through hole of the locking
bar, so that the rounded side of the contact barrel rests in
the nest (concave split level area) with the crimp tails
facing upward. To match the wire gauge to the crimp tool
die, refer to

Table A-3

Release locking bar to lock terminal in die.

NOTE

If the crimp tails are slightly out of vertical alignment, the crimp
tool automatically rotates the terminal so that the tails face

straight upward. When positioned, the locking bar fits snugly
in the space between the contact band and the core crimp tails.

Insert stripped wire core between crimp tails until ends
make contact with locking bar. Verify that wire is positioned
so that short pair of crimp tails squeeze bare wire strands,
while long pair folds over the insulation.

Squeeze handle of crimp tool until tightly closed. Tool
automatically opens after the terminal is crimped.

Raise locking bar up and remove wire lead and terminal.

Inspecting Crimps

Inspect the wire core and insulation crimps. Distortion should
be minimal.

Table A-3. Deutsch Standard Terminal Crimp: Wire Gauge

To Die

CRIMP TOOL DIE

WIRE GAUGE (AWG)

Front

Middle

16-18

sm00021

Insert stripped lead

Open jaws and raise locking bar

Insert terminal in locking bar

Squeeze crimper

Raise locking bar and remove terminal

Release locking bar to lock terminal in die

Figure A-21. Crimping a Deutsch Standard Terminal

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A-14 2009 Dyna Service: Appendix A Connector Repair

A.7

DEUTSCH SOLID BARREL MINI TERMINAL
REPAIR

DEUTSCH SOLID BARREL TERMINAL
CRIMPS

TOOL NAME

PART NUMBER

ELECTRICAL CRIMPER TOOL

HD-42879

Preparing Wire Leads For Crimping

For size 20, 16 and 12 contacts, wire ranges 26-12 AWG.

Strip wire lead removing 1/4 in. (6.4 mm) of insulation.

Adjusting Crimper Tool

See

Figure A-22

. Squeeze the ELECTRICAL CRIMPER

TOOL (Part No. HD-42879) handles to cycle the crimp
tool to open.

Remove locking pin (1) from selector knob (2).

Raise selector knob and rotate until selected wire size
stamped on wheel is aligned with "SEL. NO." arrow (3).

Loosen knurled locknut (4) and turn adjusting screw (5)
clockwise (in) until it stops.

Crimping a Barrel Contact To Wire Lead

See

Figure A-23

. Turn tool over and drop contact barrel

(1) into indentor cover (2) hole with the wire end out.

Turn adjusting screw counterclockwise (out) until contact
is flush with bottom of depression in indentor cover.
Tighten knurled locknut.

Slowly squeeze handles of crimp tool until contact is
centered between the four indentor points (3).

Insert bare wire core strands of stripped wire lead (4) into
contact barrel. Squeeze handle of crimp tool until tightly
closed. Tool automatically opens when the crimping
sequence is complete.

Remove wire lead with crimped contact from indentor.

NOTE

Tool must be readjusted when changing contact size/type.

Install pin to lock selector knob.

Inspecting Crimps

Inspect the crimp. All core wire strands are to be crimped in
the barrel.

This

HAND

tool

ust

not

used

ered

"PRESS''

defined

OSHA

CFR

1910.211

(46)

sm00023

Locking pin

Selector knob

SEL. NO. arrow

Knurled locknut

Adjusting screw

Figure A-22. Electrical Crimper Tool (HD-42879)

HOME

2009 Dyna Service: Appendix A Connector Repair A-15

HDT

- 48

- 00

JDG360-1

HEMET

RYAN

AIRPOR

T, P

. BO

X 878

HEMET

, CA.

92343-0161

(714)

929-1200

INDUSTRIAL

ODUCTS

DIVISION

HDT

- 48

- 00

JDG360-1

HEMET

RYAN

AIRPOR

T, P

. BO

X 878

HEMET

, CA.

92343-0161

(714)

929-1200

INDUSTRIAL

ODUCTS

DIVISION

sm00024

Contact barrel

Indentor cover

Indentor point

Stripped wire lead

Figure A-23. Deutsch Solid Barrel

HOME

A-16 2009 Dyna Service: Appendix A Connector Repair

A.8

DEUTSCH MINI TERMINAL REPAIR

DEUTSCH MINI TERMINAL CRIMPS

TOOL NAME

PART NUMBER

PACKARD TERMINAL CRIMPER

HD-38125-7

Preparing Wire Leads for Crimping

Strip wire lead removing 5/32 in. (4.0 mm) of insulation.

Crimping a Mini Terminal to Wire Lead

See

Figure A-24

. Compress the handles of PACKARD

TERMINAL CRIMPER (Part No. HD-38125-7) until the
ratchet (2) automatically opens.

NOTE

Always perform core crimp before insulation crimp.

Position the core crimp on die E (1) of the crimper. Be
sure the core crimp tails are facing the forming jaws.

Gently apply pressure to handles of tool until crimpers just
secure the core crimp tails.

Insert stripped wire core stands between crimp tails. Pos-
ition wire so that short pair of crimp tails squeeze bare
wire strands, while long pair squeeze over the insulation.

Squeeze handle of crimper until tightly closed. Tool auto-
matically opens when the crimping sequence is complete.

NOTE

If the crimper does not open, it can be opened by squeezing
the ratchet trigger (2).

Position the insulation crimp on nest C of the crimper. Be
sure the insulation crimp tails are facing the forming jaws.

Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is com-
plete.

Inspecting Crimps

Inspect the core and insulation crimps. Distortion should be
minimal.

sm00022

E die

Crimper ratchet trigger

Figure A-24. Packard Terminal Crimper (HD-38125-7)

HOME

2009 Dyna Service: Appendix A Connector Repair A-17

A.9

MOLEX CONNECTORS

MOLEX CONNECTOR REPAIR

TOOL NAME

PART NUMBER

MOLEX ELECTRICAL CONNECTOR
TERMINAL REMOVER

HD-48114

Separating Pin and Socket Housings

See

Figure A-25

. Depress the latch while pulling the pin and

socket housings apart.

Mating Pin and Socket Housings

Orient the latch on the pin housing to the latch pocket on
the socket housing so the rails on the outside of the pin
housings lines up with the tunnels on the socket housing.

Press the housings together until the latch clicks.

Removing Terminals

Pull the secondary lock up, approximately 3/16 in. (4.8
mm), until it stops.

Socket Housing: See

Figure A-26

. Use a small

screwdriver in the pry slot. The slot next to the
external latch provides a pivot point.

Pin Housing: See

Figure A-27

. Use needle nose

pliers to engage the D-holes in the center of the sec-
ondary lock.

NOTE

Do not remove the secondary lock from the connector housing.

See

Figure A-28

. Insert MOLEX ELECTRICAL CON-

NECTOR TERMINAL REMOVER (Part No. HD-48114)
into the pin hole next to the terminal until the tool bottoms.

Socket Housing: The pin holes are inside the ter-
minal openings.

Pin Housing: The pin holes are outside the pins.

Pressing the terminal remover to the bottom of the pin
hole, gently pull on the wire to remove wire terminal from
its cavity.

Installing Terminals

See

Figure A-29

. From the wiring diagram, match the wire

color to its numbered terminal cavity.

NOTE

Cavity numbers (1) are stamped on the housing at the ends
of the cavity rows. The cavity number can be determined by
counting the cavities up or down along the row from each
stamped number.

Orient the terminal so that the tang (2) opposite the open
crimp engages the slot (3) in the cavity.

Push the terminal into the cavity.

Gently tug on wire to verify that the terminal is captured
by the secondary lock.

With all terminals installed, push the secondary lock into
the socket housing to lock the wire terminals into the
housing.

sm00040

Figure A-25. Molex Connector: Latch

sm03332

Figure A-26. Secondary Lock Pry Slot (Socket Housing)

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A-18 2009 Dyna Service: Appendix A Connector Repair

sm02851

Figure A-27. Pull Up Secondary Lock (Pin Housing)

sm00043

Figure A-28. Molex Connector: Terminal Remover

(HD-48114)

sm00044

Cavity number

Tang

Cavity slot

Figure A-29. Molex Connector: Pin Cavities and Wire

Terminal

CRIMP TERMINAL TO LEAD

TOOL NAME

PART NUMBER

ELECTRICAL CRIMP TOOL

HD-48119

Prepare Lead

Cut the damaged terminal close to the back of the terminal
to leave as much wire length as possible.

Strip approximately 3/16 in. (4.70-5.60 mm) of insulation
from the end of the wire lead.

NOTE

The strip length is the same for both pin and socket terminals
and for wire gauges from 22 to 14.

Prepare Tool

Identify the punch/die in the jaws of the ELECTRICAL
CRIMP TOOL (Part No. HD-48119) for the wire gauge.
Refer to

Table A-4

Squeeze and release the handles to open the tool.

NOTE

The crimp tool automatically opens when the handles are
released.

See

Figure A-30

. Hold fully open tool at approximately 45

degrees.

NOTE

Do NOT tighten the locknut holding the locator bars. The bars
must float to accommodate the different terminal gauges.

HOME

2009 Dyna Service: Appendix A Connector Repair A-19

Table A-4. Crimp Tool Wire Gauge Punch/Die

PUNCH/DIE

AWG (WIRE GAUGE)

Left

Middle

18-20

Right

14-16*

* Crimp 16 AWG pin terminals in the 18-20 middle die.

sm02853

Figure A-30. Open Electrical Crimp Tool (HD-48119) at 45

Degrees

sm02854

Socket locator bar

Pin locator bar

Figure A-31. Terminal Locator Bars

Position Terminal in the Punch/Die

See

Figure A-32

. With the crimp tails up, place the terminal

through the punch/die into the square opening in the
socket locator bar.

Socket Terminal: See

Figure A-31

. A socket terminal

stops against the back face of the socket locator bar
(1).

Pin Terminal: See

Figure A-33

. The tip of a pin ter-

minal passes through the socket locator bar and stops
in the notch in the face of the pin locator bar.

See

Figure A-34

. Ratchet the handles together until the

crimp tails are held in vertical alignment between the punch
and the die.

sm02855

Figure A-32. Square Openings in Socket Locator Bar

Insert Stripped Lead

See

Figure A-35

. Insert the stripped end (wire core) between

the crimp tails at an up angle until the wire core touches the
face of the socket locator bar above the square opening.

NOTES

•

The insulation must extend through the insulation crimp
tails.

•

Insert the wire with little or no pressure. Pressing on the
lead will bend the wire core.

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A-20 2009 Dyna Service: Appendix A Connector Repair

sm02856

Figure A-33. Pin Terminal against Pin Locator Bar

sm02857

Figure A-34. Crimp Tails in Vertical Alignment between

Punch and Die

Crimp Terminal to Lead

Holding the wire lead in position touching the locator face
at an angle, quickly and smoothly squeeze the crimp tool
closed.

Final squeeze the handles to open the tool and release
the terminal.

NOTE

A stuck or jammed tool can be opened by pressing the ratchet
release lever found between the handles. Do not force the
handles open or closed.

sm02858

Figure A-35. Stripped Lead at Up Angle

Inspect Crimp

Inspect Crimp: Inspect the core and insulation crimp.

See

Figure A-36

. The core tails should be creased

into the wire strands at the core crimp (1).

Strands (2) of wire should be visible beyond the core
crimp but not forward into the terminal shell.

The insulation tails should be folded into the insulation
(3) without piercing or cutting the insulation.

Distortion should be minimal.

Test Crimp: Hold the terminal and pull the lead.

sm02859

Core crimp

Wire strands

Insulation crimp

Figure A-36. Terminal Crimp

HOME

2009 Dyna Service: Appendix A Connector Repair A-21

A.10

PACKARD 150 METRI-PACK CONNECTORS

150 METRI-PACK CONNECTOR REPAIR

General

Metri-Pack connectors are embossed with the initials (P.E.D.).

There are two types of connectors in this series:

•

Pull-to-Seat

•

Push-to-Seat

Separating Pin and Socket Housings

Bend back the external latch slightly and separate the pin and
socket halves of the connector.

Mating Pin and Socket Housings

Align the wire colors and push the pin and socket halves of the
connector together.

Removing Socket Terminal

See

Figure A-37

for pull-to-seat connector or

Figure A-38

for push to seat connector. Remove wire lock (1) from wire
end of socket housing on push-to-seat type connectors.

NOTE

For best results, free one side of wire lock first and then release
the other side.

Find the locking tang in the mating end of the connector.

NOTE

The tangs are always positioned in the middle of the chamber
and are on the same side as the external latch.

Gently insert a safety pin into the chamber about 1/8 in.
(3.2 mm).

For pull-to-seat: Stay between the terminal and the
chamber wall and pivot the end of the pin toward the
terminal body.

For push-to-seat: There is a small opening for the
pin.

When a click is heard, remove the pin and repeat the
procedure.

NOTE

The click is the sound of the tang returning to the locked posi-
tion as it slips from the point of the pin.

Pick at the tang until the clicking stops and the pin seems
to slide in deeper than it had previously. This is an indica-
tion that the tang has been depressed.

NOTE

On those terminals that have been extracted on multiple
occasions, the click may not be heard, but pivot the pin as if
the click was heard at least 3 times.

Remove the pin.

For pull-to-seat: Push on the lead to extract the ter-
minal from the mating end of the connector.

For push-to-seat: Pull on the lead to draw the ter-
minal out the wire end.

Inserting Socket Terminal

NOTE

For wire location purposes, alpha characters are stamped into
the socket housings.

See

Figure A-37

for pull-to-seat connector or

Figure A-38

for push to seat connector. Using a thin flat blade, like that
on a hobby knife, carefully bend the tang outward away
from the terminal body.

Gently pull or push on the lead to install the terminal back
into the chamber. A click is heard when the terminal is
properly seated.

Gently pull or push on the lead to verify that the terminal
is locked in place.

For push-to-seat: See

Figure A-38

. Seat wires in separate

channels of wire lock and then push channels inside
chambers at wire end of socket housing. Fully installed,
slot on each side of wire lock engages ear on socket
housing.

HOME

A-22 2009 Dyna Service: Appendix A Connector Repair

sm00027

Locate tang in chamber

Pivot pin to depress tang

Push to remove

Raise tang to install

Figure A-37. 150 Metri-Pack Connector: Pull-to-Seat

sm00028

Remove wire lock

Pivot pin to depress tang

Pull to remove

Raise tang to install

Figure A-38. 150 Metri-Pack Connector: Push-to-Seat

HOME

2009 Dyna Service: Appendix A Connector Repair A-23

Content .. 23 24 25 26 ..